Process and apparatus for making cycle saddles



Oct. 27, 1942. R. w. FAuLHABl-:R 300380 PROCESS AND APPARATUS FORMAKING CYCLE sADDLEs Filed Jue I7. 1941 2 Sheets-Sheet l Fla-'7 v 1NvENToR. ,EULA/vo w FAn/#155e :NAL I it VIWW Gct. 27, 1942. R. w. FAULHABER 2,300,380

A PROCESS AND APPARATUS FOR MAKING CYCLE SADDL'ES 'Filed June-17, 1941 sheets-sheet 2j l 5 Flarl MyW/M612 Patented Oct. 27, 1942 PROCESS AND APPARATUS FORAM'AKING CYCLE SADDLES yRoland-W. Faulhaber, Monroeville, Ohio, assgnor to The Faulhaber` Company, Monroeville,0hio,

a corporation of Ohio f appiicaaonfiuneiv, 1941, seria1,No.;39s,445

v- 18 Claims.

This invention relates to a method of making and assembling bicycle saddles and thevr like.

It has been customary heretofore to make the seat portions of bicycle saddles Iandthe like from a metal frame or base, padding or cushioning material disposed upon the fra-me or base` plate; and a covering of flexible material such as-imitation leather, leather and similar materials disposed over the padding and secured byl Stitching or other means to the frame or base plate. To secure the covering material smoothly and tightly to the irregular contours of the saddle it has been customary heretofore to shape the covering material under high pressure between dies, the material having previously been wet or otherwise treated as necessary to make it retain theshape imparted to it. The shaped covering material is then assembled over the base plate and padding and secured in position in the desired manner.

The present invention has for its objects -to simplify and reduce the cost of theV operations involved in assembling and securing'together the parts of a seat of this type, and-also to obtain a smoother, tighter, morepermanent and durable covering of the seat member. Other objects are to arrange the coveringin such amanner as to provide a smooth nished edge on the seat free of unsightly binding strips, rivets, stitching and the like; to improve and simplify the method of securing the ,covery inYY position after it has been assembled on the seat and padding; and to improve and simplify the method and apparatus for assembling a seat. Other objects will appear in the following detailed description of the preferred method and apparatus for practicing this invention.

In the accompanyingdrawings,

Figure 1 is a bottom plan View of adie looking in the direction of thearrows l-l `of Figure 2;

Figure 2 is a vertical section through a portion of the press for carrying out this invention showing the upper die raised or separated from the lower die;

Figure 3 is a view similar to Figure 2 showing the parts at the end of the working stroke of the press;

Figure 4 is a section taken on the line 4-4 Figure 3;

Figure 5 is a bottom plan View of a base plate or frame for a seat;

Figure 6 is a side elevation of the'same;

Figure 7 is a plan View of the bottom die with the seat assembled 'therein removed from the press;

Figure 8 is a bottom saddle;

Figure 9 'is a detail elevation taken on the line 9-9 of Figure 8;

Figure 10 is adetail elevationjtaken on the line Ill-l0 of Figure 8;

Figure 11 is a section taken on the line I# I l ofFigure 8; L

Figure 12 is asection vv.taken on theline l 2.-. 12 of Figure; y

Figure `13-is a'longitudinal section taken on the line |3.-I3 of Figure;

Figure 14 is aplan vewof thefastenng men1- ber used to secure-'thecovering'120l the base;

IFigure 15 lis an rvend lview taken .onthe line 15--15 of Figurell'; 'and' y Figure 16 isan end view taken on theline plan view of an assembled I6- l5 of Figurek 14.

I prefer tocarry out myinvention by thepuse of an ,ordinaryzpress vhaving Aa. reciprocating punch slide andablank holder or pressureA pad. The punch is vprovided with meansv to support the base plate of the seat, and the die `isgprovided with ,anopening shaped to receive and frictionally grip the edges of ,theassembledbase plate and covering material. covering materialis placed Iupon the die .and the base plate is mounted on thepunch. When the pressure pad and punch descend ,against the die the pressure pad rst grips the edges ofthe sheet of covering material, and the base ,plate of the seat is then forced Yby thepunch'into the opening in the die. The base plate draws with it the covering material which is pulled from 4between the upper surface oflthe die and the pressure pad and isthereby pulled tightly around the base plate. The/punch and pressure -pad then return to their retracted positionsleaving the seat andr covering material tightly gripped in the openingin 'the die A.with `.theco vering material stretched smoothly and .tightly over the seat and padding. I prefer to use `a series ,of dies and to remove eachdie from the press vafter a seat has been formed Lin it, so that veach die may be' passed on to the next operator and the covering material locked .in position in v,the base plate while the press `is forming anotherseat in another die,

Referring to the drawings, I have illustrated a reciprocating punch .or ram 2.0 mounted upon suitable press mechanism sov as vto Ybe reciprocated toward and away vfrom a die 2|,` which maybe positioned upon the bed frame or thelikerofthe The/ilat sheet of press. A pressure pad 22 is shown as secured to rods 23 which extend slidably through apertures 24 in a portion of the punch and have their upper ends headed or shouldered as shown at 25 to support the pressure pad with respect to the punch. Springs 26 surround the rods 23 and cause the pressure pad 22 to be held down with a predetermined pressure. The die 2| is provided with an opening to receive and frictionally engage the covered seat. Preferably the die is formed with an opening 2l within which a rubber ring 28 is secured in any suitable manner, as by capscrews 2S. The rubber ring 28 is formed with an opening 33 to fit the seat. The seat is preferably formed from a sheet metal base member 3| which is drawn to the desired shape and which, as illustrated, includes an upper seat surface, a narrow nose portion 32 and a fiared skirt 33 at the rear portion. The edge of the base member is formed with an inturned flange 34 throughout the greater portion of its periphery. Inwardly projecting bolts 35 may be secured to the base 3| to provide means for attaching the springs to the finished seat. Cushioning or padding material 36 is provided and is preferably cemented or otherwise secured to the upper surface of the base 3| to hold it in position during the covering operation.

The pressure pad 22 of the press is formed with an opening 3'! shaped to conform to the outline of the base 3| but of sufcient size to permit the base to pass therethrough. The punch 20 includes a downwardly projecting head 38 which is shaped to enter the base member 3| from the underside and distribute pressure over the inner surface of the base member. As shown in Figures 2, 3, and 4 the head 38 is small enough topass within the inturned. flange 34 of the base member and'carries spring pressed latches 39 arranged to engage under the flange 34 and hold the base onthe punch. As illustrated, the latches`39 are slidably mounted in guides 43 on the head`38, and have upturned spaced ends pressed apart by a spring 4|.

After the base member 3| has been formed and the padding 36 secured thereto, it is placed over the head 38 of the punch 2|) and retained in position by snapping the latches 33 under the flange 34. A sheet 42 of suitable covering material is then laid over the die 2| and centered over the opening 33. The press is then tripped to cause the punch l5 to descend. The pressure pad 22 first engages the edges of the sheet 42 of covering material and grips these edges against the upper surface of the die 2|. tinued movement of the punch causes the same to slide on the rods 23 so that the pressure pad 22 remains in position gripping the edges of the covering material, under the pressure determined by the strength of the springs 25 while the head 38 pushes the baseY member 3| through the opening 3l in the pressure pad and into the opening in the die 2|. This movement of the base member 3| engages the sheet of covering material 42 and draws the same into the die. Movement of the covering material is resisted by the frictional grip. of its edges between the pressure pad 22 and the. die 2|, so that the covering material is stretched and pulled tightly and smoothly about the base member 3| and the padding 36. As soon as the base member enters the opening 30 in the rubber ring 28 of the die, additional stretching and forming force is `exerted on the covering material 42 by the friction of the rubber ring. The opening 30 conforms to Cone the base member 3|.

the contour of the seat and is made suciently smaller than the base 3| and covering material 42 to exert the desired tension on the covering material. This tension is exerted uniformly about the irregular shape of the base and acts to smooth out all wrinkles and impose a tension on the material that is substantially uniform in all directions and in all parts of the seat.

At the completion of the stroke the parts are in substantially the position illustrated in Figure 3 with the covering material 42 stretched and pulled` tightly and smoothly about the base member 3| and the padding 33 and held in this position by the frictional grip provided by the rubber ring 28' around the entire periphery of It will be understood that the base can be pushed as far into the die openling 30 as is necessary to properly smooth the covering material and clamp the same in position.

The punch 2G and pressure pad 22 are then retracted, completing the cycle of the press. When the punch moves upwardly, the latches 33 snap out of their position beneath the flange 34, leaving the base and covering material in the die With the free edge of the material projecting past the edge of the base. `In accordance with the preferred method of manufacture the die 2| with the assembled seat clamped therein is removed from the press and conveyed to a position or station at which the securing of the covering material is completed. Another similar die is then placed on the bed frame of the press and the operation is repeated.

The die 2| removed from the press with the assembled seat frictionally gripped therein is illustrated in Figure 7. To complete the seat the free edge ofthe covering material is turned inwardly and secured in place in any desired manner, after which the completed seat is forced out of the die and thel die returned to the press to beusedagain. Thus the covering of the seat is completed Without soaking, pressing, or other preliminary operations on the covering material, and a smoother, tighter covering job is obtained than is 'possible with the methods and apparatus heretofore used.

A preferred .arrangement for securing the free edge of the covering material in position and completing the seat is illustrated in Figures 8 to 16 inclusive.' While thefseat remains in the die 2|, the edge of1 the covering material is turned inwardly and secured by a sheet metal retainer 43. This retainer comprises a skeleton sheet metal member shaped to the general conformation of the under side of the base. It is preferably made by die stamping from a resilient spring metal and is provided with a large opening 44 in the wide rear portion and a smaller opening 45 in the nose. The rear of the frame portion is split as indicated at 46 with the two parts adjacent the split overlapping.

The retainer is made of a size suiiiciently large so that it must be pressed into position on the underside of the saddle base past the flange 34. The resiliency of the retainer causes it to press outwardly against the inturned portion of the seat covering throughout the entire periphery of the base. The height of the retainer is sufficient to cause its lower edge to compress and grip the covering material against the upper surface of the flange 34. When the retainer is pressed into the seat past the flange 34, it exerts sufficient friction on the covering material to pull it tightly around the flange. Thus the tensionimposed on the material bythe die isnot released and the cover is firmly secured in-place.

The split ends 4B when once'secured-in posi-- reflector glass 5l 'in position on the rear of the v seat.

Although I have described a preferred embodiment of my invention in considerable .detail, it

Will be understood that many Variations can be.v

made therein. For eXampleVthe. opening 3D in the die may be formed in any material..which Will provide the desired frictional grip onY the covering material, although `the rubberv ring 28V is preferred. Metalrmayl be used bycarefully shaping the opening to have just the desired clearance, less than the thickness of the covering material, around Ythe entire base, but a yieldable substance is preferred because the shaping of the opening need not be so exact, and.. because it will accommodate a considerable manufacturing tolerance in the size and shape of the` base members. Likewise, any desired means. may be employed for securing the free edgeof the covering material to the base. so long as the edge is pulled tight and fastened before the gripping force of the die is released. Many other modifications may be resorted to Without departing from the scope of the invention as defined.

in the following claims.

I claim:

l. The-process of making seats for cycle saddles and the like comprising frictionally gripping the edges of a sheet of flexible covering material,

forcing a base member against said material .so

as to pull said edges free and :simultaneously pull said covering material tightly aboutsaid base member, and securing. the edgesof said covering material to said `base member.

2. The process of making seats for cycle saddles and the like comprising frictionally gripping the edges of a sheet of exible covering material, forcing a base member against said material so as to pull said edges free and simultaneously pull said covering material tightly about said base under tension, and securing the edges of said covering material to said base member before releasing the tension.

3. The process of making a seat or the like comprising disposing a sheet of ilexible covering material over an aperture in a forming member, frictionally gripping the edges of said sheet of material around said aperture, forcing a base member against said covering material and into said aperture so as to pull said edges free and simultaneously pull said covering material tightly about said base member, and securing the edges of said covering material to said base member.

4. The process of making a seat or Athe like comprising disposing a sheet of exible covering material over an aperture in a forming memsimultaneously pull said covering material tightly about said base member under tension, and securing the edges of said covering material to said base member before releasing the tension.

a formingmember. of suchLsize-andshapeas--to frictionally grip vthe assembled-seat.aroundits entireperiphery, forcing -a-base memberagainst said materialand into-said-aperture sothat theedgesof said aperture inthe forming .-member grip the-covering material-against `a periphery# of thegbase membercand lpull' the covering.ma-

terial -tightly over the base membenand securing.

covering material .to saidbase members 6.-!1he process y'ofmakinga seat or thelikel? comprising disposing a sheet of exible covering material over an aperture inv a forming member of such size and shape as to frictionally grip thev assembled seat around its entire periphery,forc ing a base-member against saidniaterial and into said aperture so that the edges of said aperture inthe forming Vmember grip.` the v covering ma-A` v terial against the periphery of the base member and stretch saidV material tightly. over the. base4r member, securing the edges of the--coveringmaterial to the seat` While `the -base member and .f covering material .are gripped-in said aperture, V and Ythereafter removingthe assembled seat from the aperture. f 7. The process of making Aa seat for a cycle sad-V` dle or the like vcomprising disposing a `sheet of flexible covering material over aresilient forming member-having Walls defining an aperture of such i size and shape as` to frictionally grip the assembled seat around its entire periphery, forcinga base Vmember against said material and into and Yalong the Walls of said formingv member.v defining said v aperture so that said Walls gripv the covering material against the periphery of the base mem-f ber and pull the coveringmaterialtightly over the base member, and securinggthefree edges of said covering. material to said base member.'

8. The Vprocess of making a seat for a cycle..

saddle or the like comprising. disposing a sheetl of exible covering material over a rubber form.

r ing member. having Walls defining an aperture.

of such size and yshape as tofrictionallygrip the. assembled seat around its entire periphery and of greater depth thanv the periphery of the z assembled seat, forcing a base member against said f material and into andalong said walls dening.. said` aperture so that said walls grip the'covering material against the `periphery of the base member and pull the covering material tightly over..A

the base member, and securing the free edges. of said coveringmaterial to said base memev` ber while Athe base and covering material.- are n gripped by said Walls.

9. The process of making a seat for arcycle saddle or the like comprising. covering a vbase member with flexible covering material lay-dis-` posing a sheet of coveringmaterial over a die having walls dening an opening of such'. size as to frictionally grip the vperiphery of the assembled base member and covering material, gripping the edges of said sheet of covering. ma-

terial around the opening in the die, forcingthe base member against the covering materialand@ into the vopening in said die so :as to pull the.; covering `material tightly 'about .the basemember.: g.

and grip the covering material between the base member and the Walls of the die dening the opening and securing the free edges of the covering material to the base member.

10. The process of making a seat for a cycle saddle or the like comprising covering a base 5. The proclzesscfA nrriaking ia seat for a fcycl'e'f.4 l saddle orthe like comprising disposing .la sheet'a of exiblecovering material -over anaperturekin-l memberwith flexible covering material by disposinga sheet of coveringmaterial over a die having resilient walls defining an opening ofA such size astoifrictionally grip the peripheryof the assembled base member and covering material, gripping V,the edges of said sheet of covering. material around the opening in the die,y forcing the basemember against the covering material and intoV and along the walls of said diedefining Athe opening so as to pull the covering material tightly aboutthe basemember and grip the covering material between the base member and the walls of the die defining the opening, and securingthe free edges of the covering material to the .base

member... V 4

11. The processof making a seat for a cycle saddle or the like comprising covering a base membenwith flexible covering material byV disposing a. sheet of covering material over a die having rubber lwalls dening an opening of such size as tofrictionally grip the periphery ofi-,thev

assembled base member and covering material, gripping the edges of said sheet of covering material around the opening in the die, forcing the baseV member against rthe covering material and into and along the walls ofsaid die defining the opening so as toV pull the covering material vtightly about the base member and grip the covering material between the base member and the rubber walls of the die defining the opening securing the free edges of the covering material to the base member while the base membery and covering material are gripped in the die, and removing the assembled seat from the die.,

12. The process of making a seat or theV like like comprising a die having an opening extend- 13. The process ofmaking ay seat or the like comprising forming a metal base member with a depending skirt terminating in an inturned flange, stretchinga sheet of .covering material overthe convex side of said base member by gripping the covering materialbetween the skirt of said base member and a frictional surface and moving said base member relativeto said surface, turning the edge of the covering material inwardly over the inturned ange of said base member, and forcing a retaining member into the concave side of the base member so as to grip the covering material betweenxthe retaining member and the base member.

14. The process of making a seat or the like comprising forming a metal .base member with a depending skirt terminating in an inturned flange, stretching a sheet of covering material over the convex side of saidzbase member' by gripping the covering material between the skirt of said base member and a frictional surface and moving said -base memberv relative to.-said sur-` face, turning.v the edge-of the covering material inwardly over the inturned flange of said basse member, and forcing a retaining member into the concave side of the base member so as to frictionally engage the covering material at the edge of said inturned flange and pull the material tightly about the flange, and seating said retaining member under said inturned flange to grip the covering material between the retaining member and the base member.

15. The process of making a seat or the like comprising forming a metal base member with a depending skirt terminating in an inturned ange, stretching a sheet of covering material over the convex side of said base member by gripping the covering vmaterial between the skirt of said base member and a frictional surface and moving said base member relative to said surface, ,turning the edge of the covering material inwardly over the inturned flange of said base `member, and, before releasing the stretching force applied by said frictional surface, forcing a retaining member into the concave side of the base member so as to frictionally engage the covering material at the edge of said inturned flange and pull the material tightly about the flange, and seating said retaining member under said inturned flange to grip the covering material between the retaining member and the base member.

16. Apparatus for making cycle seatsv and the ing therethrough, the opening having the shape of the desired external contour of the finished seat, and a punch arranged to force a-seat base member and a sheet of covering material into the opening in said die, the walls of said die deining said opening being arranged to frictionally .grip said covering material and pull the same tightly about said base member as the base member is forced into said opening.

17. Apparatus for making cycle seats and the like comprising a die of resilient material having an opening extending therethrough, the opening having the shape of the desired external contour of the finished seat, and a punch arranged to force a seat base member and a sheet of covering material into the opening in said die, the resilient walls of said diedeflning said opening being arranged to frictionally grip said covering material and pull the same tightly about said base member as the base member is forced into said opening.

18. Apparatus for making cycle seats and the like comprising a die having an opening extending therethrough, the opening having the shape of the desired external contour of the finished seat, a pressure pad arranged to yieldably grip the edge of a sheet of covering material against the surface of said die, and a punch arranged to force a seat base and the sheet of covering material gripped by said pressure pad into the opening in said die and thereby pull said material from between said pressure pad and the surface of said die, the walls of said die defining said opening being arranged to frictionally grip said material against the periphery of said base member.

ROLAND W. FAULHABER. 

